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Exhaust 3500 2005
Service Manual
36 pgs632.6 Kb0

Dodge Exhaust 3500 2005, Exhaust 2500 2005, Exhaust 1500 2005 Service Manual

DR/DH EXHAUST SYSTEM 11 - 1
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION
GAS ENGINES ........................2
5.9L DIESEL ..........................3
DIAGNOSIS AND TESTING
GAS ENGINE .........................4
DIESEL ENGINE .......................4
SPECIFICATIONS
TORQUE .............................5
CONVERTER-CATALYTIC
REMOVAL
3.7L/4.7L ENGINE ......................7
5.7L ENGINE ..........................8
5.9L DIESEL ENGINE ...................8
8.3L ENGINE ..........................9
INSTALLATION
3.7L/4.7L ENGINE ......................9
5.7L ENGINE .........................10
5.9L ENGINE DIESEL ..................10
8.3L ENGINE .........................11
PIPE EXHAUST
REMOVAL
3.7L/4.7L/5.7L ENGINE ..................11
5.9L DIESEL .........................12
8.3L ENGINE .........................12
INSTALLATION
3.7L/4.7L/5.7L ENGINE .................13
5.9L DIESEL .........................13
8.3L ENGINE .........................14
HEAT SHIELDS
MUFFLER
REMOVAL
3.7L/4.7L/5.7L ENGINE .................17
8.3L ENGINE .........................18
5.9L DIESEL ENGINE ..................18
INSTALLATION
3.7L/4.7L/5.7L ENGINE .................19
8.3L ENGINE .........................19
5.9L DIESEL ENGINE ..................20
TAILPIPE
REMOVAL
3.7L/4.7L/5.7L ENGINE .................20
5.9L DIESEL .........................21
8.3L ENGINE .........................21
INSTALLATION
3.7L/4.7L/5.7L ENGINE .................22
5.9L DIESEL .........................22
8.3L ENGINE .........................23
TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING
TURBOCHARGER BOOST PRESSURE .....23
TURBOCHARGER
REMOVAL
TURBOCHARGER .....................27
TURBOCHARGER OIL DRAIN TUBE .......28
INSTALLATION
TURBOCHARGER .....................30
TURBOCHARGER OIL DRAIN TUBE .......31
WASTEGATE - ELECTRONIC ACTUATOR
CHARGE AIR COOLER AND PLUMBING
DIAGNOSIS AND TESTING
CHARGE AIR COOLER SYSTEM - LEAKS . . . 33
11 - 2 EXHAUST SYSTEM DR/DH
EXHAUST SYSTEM
DESCRIPTION GAS ENGINES
Exhaust System - 3.7L Engine - Typical
CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes.
Exhaust System 4.7L Engine - Typical
DR/DH EXHAUST SYSTEM 11 - 3
The federal gasoline engine exhaust system consists of engine exhaust manifolds, exhaust pipes, catalytic convert­er(s), extension pipe (if needed), exhaust heat shields, muffler and exhaust tailpipe , ,
The California emission vehicles exhaust system also contains the above components as well as mini catalytic con­verters added to the exhaust pipe.
Exhaust System 5.7L Engine - Typical
The exhaust system must be properly aligned to prevent stress, leakage and body contact. Minimum clearance between any exhaust component and the body or frame is 25.4 mm (1.0 in.). If the system contacts any body panel, it may amplify objectionable noises from the engine or body.
5.9L DIESEL
CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes.
The diesel engine exhaust system consists of an engine exhaust manifold, turbocharger, exhaust pipe, resonator, extension pipe, catalytic converter, muffler and exhaust tailpipe.
The exhaust system must be properly aligned to prevent stress, leakage and body contact. The exhaust compo­nents should be kept a minimum of 25.4 mm (1.0 in.) away from the body and frame. If the system contacts any body panel, it may amplify objectionable noises from the engine or body.
11 - 4 EXHAUST SYSTEM DR/DH
DIAGNOSIS AND TESTING GAS ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR LEAKING EXHAUST GASES
CAUTION: When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust system.
3. Broken or rusted out exhaust
pipe.
4. Exhaust pipe leaking at manifold
flange.
5. Exhaust manifold cracked or
broken.
6. Leak between exhaust manifold
and cylinder head.
7. Catalytic converter rusted or
blown out.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
3. Replace exhaust pipe.
4. Tighten/replace flange attaching nuts/bolts.
5. Replace exhaust manifold.
6. Tighten exhaust manifold to cylinder head bolts.
7. Replace catalytic converter assy.
Replace restricted part if necessary.
DIESEL ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
3. Broken or rusted out exhaust
pipe.
4. Exhaust pipe leaking at manifold
flange.
5. Exhaust manifold cracked or
broken.
6. Leak between exhaust manifold
and cylinder head.
7. Turbocharger mounting flange
cracked.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
joints.
system.
3. Replace exhaust pipe.
4. Tighten/replace flange attaching nuts/bolts.
5. Replace exhaust manifold.
6. Tighten exhaust manifold to cylinder head bolts. Replace gasket if necessary.
7. Remove turbocharger and inspect. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER ­REMOVAL).
Replace restricted part if necessary.
DR/DH EXHAUST SYSTEM 11 - 5
SPECIFICATIONS TORQUE
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Bolt-Adjusting Strap 23 - 200 Nuts-Air Heater Power Supply 14 - 124 Bolts-Air Inlet Housing 24 18 ­Nuts-Cab Heater Supply/Return Line 24 18 ­Nuts-Exhaust Clamp 54.3 40 ­Bolts-Exhaust Manifold to Cylinder Head-(Diesel Engine) 43 32 ­Bolts-Exhaust Manifold to Cylinder Head-(5.9L) 31 23 ­Bolts-Exhaust Manifold to Cylinder Head-(8.3L) 22 - 195 Bolts-Exhaust Pipe to Manifold 31 23 ­Bolts-Generator Mounting 41 30 ­Bolts-Charge Air Cooler Mounting 10 - 90 Nuts-Charge Air Cooler Duct 11 - 95 Bolt-Generator to Block-Diesel 24 18 ­Nuts and Bolts-Heat Shield 11 - 95 Nuts-Heat Shield-Diesel 24 18 ­Electronically Controlled Wastegate Command Valve 34 25 ­Turbocharger flange studs 24 18 ­Nuts-Turbocharger Mounting 43 32 ­Bolts-Turbocharger Oil Drain Tube 24 18 ­Fitting-Turbocharger Oil Supply Line 24 18 ­Nut-Turbocharger V-Band Clamp 5.6 - 70 Turbocharger Oil Supply fitting (at Turbocharger) 36 27 ­Turbocharger Oil Supply fitting (at lube filter head) 24 18 -
11 - 6 EXHAUST SYSTEM DR/DH
SPECIAL TOOLS
TURBOCHARGER TESTER 9022
DR/DH EXHAUST SYSTEM 11 - 7
CONVERTER-CATALYTIC
DESCRIPTION
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THERE­FORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter.
The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the con­verter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage.
Unleaded gasoline must be used to avoid contaminating the catalyst core.
50 State emission vehicles incorporate two mini catalytic converters located after the exhaust manifolds and before the inline catalytic converter.
OPERATION
The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the exhaust stroke of the engine. This process aids in reducing emissions output.
REMOVAL
3.7L/4.7L ENGINE
1. Raise and support vehicle.
2. Saturate the bolts and nuts with heat valve lubri­cant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor electrical connectors.
4. Remove clamps (3 and 5) and nuts.
5. Remove LH catalytic converter (7) to exhaust man­ifold bolts (2).
6. Remove LH catalytic converter (7).
7. Remove RH catalytic converter ( 3) to exhaust manifold bolts (2).
8. Remove RH catalytic converter (3).
11 - 8 EXHAUST SYSTEM DR/DH
5.7L ENGINE
1. Raise and support vehicle.
2. Saturate the bolts and nuts with heat valve lubri­cant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor electrical connectors.
4. Remove clamps and nuts (4).
5. Remove catalytic converter to exhaust manifold bolts (2) and nuts (1).
6. Remove catalytic converter assembly (3).
5.9L DIESEL ENGINE
WARNING: IF TORCHES ARE USED WHEN WORK­ING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubri­cant. Allow 5 minutes for penetration.
3. Remove clamp bolts from exhaust pipe to catalytic converter clamp ( 5).
NOTE: Do not remove nut from T-Bolt. Only remove nut far enough, so that the T end can be removed from the clamp.
NOTE: The catalytic converter to exhaust manifold clamp is not reusable. Always use a new clamp when reinstalling the catalytic converter.
4. Loosen the nut from clamp (1) at turbocharger.
5. Remove the T bolt end of the fastener, from the clamp (1).
6. Spread the clamp, and remove the catalytic converter (4) and front exhaust pipe (2) from the vehicle.
7. Discard the clamp.
8. Remove front exhaust pipe to catalytic converter clamp (3).
9. Separate front exhaust pipe (2) from catalytic converter (4).
DR/DH EXHAUST SYSTEM 11 - 9
8.3L ENGINE
1. Raise and support vehicle.
2. Saturate the bolts and nuts with heat valve lubri­cant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor electrical connectors.
4. Remove LH exhaust pipe to manifold bolts (2), retainers and nuts (1).
5. Remove LH catalytic converter to muffler clamp nuts (4).
6. Rotate LH catalytic converters (6) from the muffler (5).
7. Remove RH exhaust pipe to manifold bolts (2), retainers and nuts (1).
8. Remove RH catalytic converter to muffler clamp nuts (4).
9. Rotate RH catalytic converter (3) from the muffler (5).
10. Remove clamps and nuts (4).
INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core.
INSTALLATION
3.7L/4.7L ENGINE
1. Install RH catalytic converter to exhaust clamp (4) on RH catalytic converter (3) and position into exhaust pipe (5).
2. Install and hand tighten RH catalytic converter to exhaust manifold bolts (1).
3. Install LH catalytic converter to RH catalytic con­verter clamp (6) on RH catalytic converter (3).
4. Position LH catalytic converter (7) into RH catalytic converter (3).
5. Install and hand tighten LH catalytic converter to exhaust manifold bolts (1).
6. Tighten catalytic converter to exhaust manifold bolts (1) to 31 N·m (23 ft. lbs.).
7. Tighten all clamp nuts (4 and 6) to 52.2 N·m (40 ft. lbs.) torque.
8. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjust­ments, if needed.
9. Lower the vehicle.
10. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
11 - 10 EXHAUST SYSTEM DR/DH
5.7L ENGINE
1. Install catalytic converter to exhaust clamp (4) on catalytic converter (3) and position into exhaust pipe (5).
2. Make sure the alignment tang on catalytic con­verter (3) is fully seated in the notch on the exhaust pipe (5).
3. Install catalytic converter to exhaust manifold bolts (2) and nuts (1).
4. Tighten catalytic converter to exhaust manifold bolts (2) to 31 N·m (23 ft. lbs.).
5. Tighten catalytic converter to exhaust pipe clamp nuts (4) to 52.2 N·m (40 ft. lbs.) torque.
6. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjust­ments, if needed.
7. Lower the vehicle.
8. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
5.9L ENGINE DIESEL
NOTE: The catalytic converter to exhaust manifold clamp is not reusable. Always use a new clamp when reinstalling the catalytic converter.
1. Position the catalytic converter (4) onto the front exhaust pipe (2) until the alignment tab is seated into the alignment slot of the catalytic converter (4).
2. Install catalytic converter (4) into the exhaust pipe (6) onto the until the alignment tab is seated into the alignment slot of exhaust pipe (6).
3. Position front exhaust pipe (2) onto turbocharger and install new clamp (1). Tighten the nuts to 11 N·m (100 in. lbs.) torque.
4. Install the exhaust clamp (5) at the exhaust pipe (6) and catalytic converter (5) connection. Tighten the clamp nuts to 54.2 N·m (40 ft. lbs.) torque.
5. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Make the necessary adjust­ments, if needed.
6. Lower the vehicle.
7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
DR/DH EXHAUST SYSTEM 11 - 11
8.3L ENGINE
1. Make sure catalytic converters (3, 6) and mufflers (5) are free of burrs.
2. Insert RH catalytic converter (3) into muffler (5).
3. Make sure the alignment tang on the catalytic con­verter (3) seats in the alignment slot on the muffler (5).
4. Position the catalytic converter (3) to the exhaust manifold. Install and hand tighten bolts (2) , retain­ers and nuts (1).
5. Insert LH catalytic converter (6) into muffler (5).
6. Make sure the alignment tang on the catalytic con­verter (6) seats in the alignment slot on the muffler (5).
7. Position the catalytic converter (6) to the exhaust manifold. Install and hand tighten bolts (2), retain­ers and nuts (1).
8. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Clearance between catalytic converter and frame is 15 mm (.59 inch). Make the necessary adjustments, if needed.
9. Tighten catalytic converter to exhaust manifold bolts (2) to 20.3 N·m (15 ft. lbs.) torque.
10. Tighten the clamp nuts to 54.2 N·m (40 ft. lbs.) torque.
11. Lower the vehicle.
12. Start the engine and inspect for exhaust leaks. and exhaust system. Repair exhaust leaks as necessary.
PIPE EXHAUST
REMOVAL
3.7L/4.7L/5.7L ENGINE
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubri­cant. Allow 5 minutes for penetration.
3. Remove exhaust pipe to manifold bolts, retainers and nuts.
4. Remove the clamp nuts.
5. Remove the exhaust pipe.
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